Fiber optic cables with multiple stacks of optical fiber ribbons

ABSTRACT

A fiber optic cable includes multiple differently sized stacks of optical fiber ribbons. The stacks include a central stack that is approximately centrally located in a jacket passage and peripheral stacks positioned radially around the central stack. A difference exists between the dimensions of the central stack and the dimensions of one or more of the peripheral stacks. Another fiber optic cable has multiple longitudinally extending stacks of optical fiber ribbons that are within a jacket passage. The stacks include a central stack that is approximately centrally located in the jacket passage, and peripheral stacks positioned radially around the central stack. Buffer encasements that respectively contain the peripheral stacks are longitudinally stranded around the central stack. Each buffer encasement includes a longitudinally extending interior surface that extends around and defines a longitudinally extending passage that contains the respective peripheral stack, and each interior surface closely bounds and engages a substantial portion of the periphery of the respective peripheral stack. Another fiber optic cable includes multiple optical modules within a longitudinally extending jacket and longitudinally stranded around a central member. Each optical module includes a stack of optical fiber ribbons enclosed in a buffer encasement. Each buffer encasement includes a longitudinally extending interior surface that extends around and defines a longitudinally extending passage that contains the respective stack, and the interior surface closely bounds and engages a substantial portion of the periphery of the respective stack.

FIELD OF THE INVENTION

The present invention pertains to fiber optic cables and, more particularly, to fiber optic cables with multiple stacks of optical fiber ribbons.

BACKGROUND OF THE INVENTION

Optical fiber is a very popular medium for large bandwidth applications, and as a result there is a demand for fiber optic cables with greater numbers of optical fibers. In response to demands for increased optical fiber count in fiber optic cables, optical fiber ribbons have been developed. Optical fiber ribbons are planar arrays of optical fibers that are bonded together as a unit. Optical fiber ribbons are advantageous because many ribbons can be stacked on top of each other to form a stack of optical fiber ribbons.

It is conventional for stacks of optical fiber ribbons to be incorporated into two different types of fiber optic cables that are generally referred to as “central-core” and “loose-tube” cables. In the central-core design, a stack of optical fiber ribbons are contained within a central tube, which is located at the center of the fiber optic cable. Further, strength members are positioned between the central tube and an outer plastic jacket of the cable. In contrast, loose-tube fiber optic cables typically include a number of relatively small buffer tubes that are positioned around a central strength member, and each buffer tube encloses a stack of optical fiber ribbons. The buffer tubes are longitudinally stranded around the central strength member, meaning that the buffer tubes are rotated around the central strength member along the length of the fiber optic cable.

In an effort to increase the density of optical fibers within fiber optic cables, different arrangements of stacks of optical fiber ribbons have been proposed. For example, U.S. Pat. No. 5,878,180 discloses a fiber optic cable with uniform stacks of optical fibers in side-by-side arrangements.

Whereas advancements have been made in the area of increasing the density of optical fibers within fiber optic cables, further advancements and options in this area would be beneficial.

SUMMARY OF THE INVENTION

The present invention provides advancements and options related to increasing the density of optical fibers within fiber optic cables. For example, in accordance with one aspect of the present invention, a fiber optic cable includes multiple differently sized stacks of optical fiber ribbons. More specifically, each of those stacks is positioned within a passage defined by a jacket. The stacks include a central stack that is approximately centrally located in the jacket passage and peripheral stacks positioned radially around the central stack. In an end elevation view thereof, the periphery of each stack defines a first cross-dimension between a first pair of opposite sides that are defined by edges of the optical fiber ribbons of the stack. In the end elevation view thereof, each stack further defines a second cross-dimension between a second pair of sides that are defined by one of the lateral surfaces of one of the optical fiber ribbons of the stack and one of the lateral surfaces of another of the optical fiber ribbons of the stack. A difference exists between the dimensions of the central stack and the dimensions of one or more of the peripheral stacks. For example, the first cross-dimension of the central stack can be different from the first cross-dimension of one or more peripheral stacks and/or the second cross-dimensions of the central stack can be different from the second cross-dimension of one or more peripheral stacks. For example, optimum packing efficiency may be achieved with the central stack being wider than the peripheral stacks. Preferably a plurality of buffer encasements respectively contain the stacks, and each buffer encasement includes a longitudinally extending interior surface. For each buffer encasement, the interior surface thereof extends around and defines a longitudinally extending passage that contains the respective stack, and each interior surface closely bounds and engages the periphery of the respective peripheral stack. Preferably the buffer encasements are thin.

In accordance with another aspect of the present invention, a fiber optic cable has a jacket extending in a longitudinal direction and defining a longitudinally extending jacket passage. Multiple longitudinally extending stacks of optical fiber ribbons are within the jacket passage. The stacks include a central stack that is approximately centrally located in the jacket passage, and peripheral stacks positioned radially around the central stack. Buffer encasements that respectively contain the peripheral stacks are longitudinally stranded around the central stack. Each buffer encasement includes a longitudinally extending interior surface that extends around and defines a longitudinally extending passage that contains the respective peripheral stack, and each interior surface closely bounds and engages a substantial portion of the periphery of the respective peripheral stack. In accordance with one example, the fiber optic cable further includes a longitudinally extending central member, which can be a strength member or a spacer, defining a longitudinally extending central passage that contains the central stack, and the buffer encasements are longitudinally stranded around the central member. The exterior surface of the central member can define a generally polygon-like shape having a number of sides that corresponds to the number of peripheral stacks. In addition, the exterior surface of the central member can define a generally round shape. Further, the exterior surface of the central member can define lay lengths that correspond to the lay length defined by the peripheral stacks.

In accordance with another aspect of the present invention, a fiber optic cable includes multiple optical modules within a longitudinally extending jacket and longitudinally stranded around a central member. Each optical module includes a stack of optical fiber ribbons enclosed in a buffer encasement. Each buffer encasement includes a longitudinally extending interior surface that extends around and defines a longitudinally extending passage that contains the respective stack, with the interior surface closely bounding and engaging a substantial portion of the periphery of the respective stack. Preferably the buffer encasements are thin.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 respective view of an optical module in accordance with a first embodiment of the present invention.

FIG. 2 is an end elevation view of the optical module of FIG. 1.

FIG. 3 is an isolated perspective view of an optical fiber ribbon of the optical module of FIG. 1.

FIG. 4 is an isolated end elevation view of a stack of optical fiber ribbons of the optical module of FIG. 1.

FIG. 5 is an end elevation view of the optical module of FIG. 1 in a skewed configuration, in accordance with the first embodiment of the present invention.

FIG. 6 is partially schematic, isolated end elevation view of a buffer encasement of the optical module of FIG. 1.

FIG. 7 is a perspective view of an optical module in accordance with a second embodiment of the present invention.

FIG. 8 is a partially schematic, end elevation view of an optical module in accordance with a third embodiment of the present invention.

FIG. 9 is a partially schematic, end elevation view of an optical module in accordance with a fourth embodiment of the present invention.

FIG. 10 is a perspective view of an optical module in accordance with a fifth embodiment of the present invention.

FIG. 11 is an elevation view of the optical module of FIG. 10.

FIG. 12 is perspective view of an optical module in accordance with a sixth embodiment of the present invention.

FIG. 13 is an end elevation view of the optical module FIG. 12.

FIG. 14 is an end elevation view of an optical module in accordance with a seventh embodiment of the present invention.

FIG. 15 diagrammatically illustrates an assembly of manufacturing equipment that is operative for manufacturing optical modules, in accordance with several methods of the present invention.

FIG. 16 is a schematic end elevation view of a fiber optic cable in accordance with an eighth embodiment of the present invention.

FIG. 17 is a schematic end elevation view of a fiber optic cable in accordance with a ninth embodiment of the present invention.

FIG. 18 is a schematic end elevation view of a fiber optic cable in accordance with a tenth embodiment of the present invention.

FIG. 19 is a schematic end elevation view of a fiber optic cable in accordance with an eleventh embodiment of the present invention.

FIG. 20 is a schematic an end elevation view of a fiber optic cable in accordance with a twelfth embodiment of the present invention.

FIG. 21 is a schematic end elevation view of a fiber optic cable in accordance with a thirteenth embodiment of the present invention.

FIG. 22 is an isolated perspective view of a central member of a fiber optic cable in accordance with a first version of the thirteenth embodiment of the present invention.

FIG. 23 is an isolated perspective view of a central member of a fiber optic cable in accordance with a second version of the thirteenth embodiment of the present invention.

FIG. 24 is a schematic end elevation view of a fiber optic cable in accordance with a fourteenth embodiment of the present invention.

FIG. 25 is a schematic end elevation view of a fiber optic cable in accordance with a fifteenth embodiment of the present invention.

FIG. 26 is a schematic end elevation view of a fiber optic cable in accordance with a sixteenth embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

FIGS. 1-14 illustrate optical modules 30 a, 30 b, 30 c, 30 d, 30 e, 30 f, 30 g in accordance with preferred embodiments of the present invention. Methods of manufacturing the optical modules 30 a, 30 b, 30 c, 30 d, 30 e, 30 f, 30 g are described with reference to FIG. 15, which diagrammatically illustrates an assembly of manufacturing equipment. Each of the optical modules 30 a, 30 b, 30 c, 30 d, 30 e, 30 f, 30 g in isolation can be characterized as a fiber optic cable, or each of the optical modules can be a component of a fiber optic cable that includes other components, such as an outer jacket that surrounds one or more optical modules. FIGS. 16-26 illustrate such fiber optic cables and components thereof. Accordingly, this Detailed Description of the Invention section includes an Optical Modules subsection, a Methods of Manufacturing Optical Modules subsection, and a Fiber Optic Cables subsection.

Optical Modules

First Embodiment

FIGS. 1 and 2 are perspective and end elevation views, respectively, of an optical module 30 a in accordance with a first embodiment of the present invention. The optical module 30 a extends in a longitudinal direction and is uniform along its length. The optical module 30 a includes a longitudinally extending ribbon stack 32 a. The ribbon stack 32 a is uniform along its length and is a stack of longitudinally extending optical fiber ribbons 34. The optical module 30 a further includes a longitudinally extending buffer encasement 36 a, which is preferably in the form of a thin sheath, that is uniform along its length and extends around and closely encases the ribbon stack 32 a. The buffer encasement 36 a can also be referred to or characterized as an enclosure. The buffer encasement 36 a is preferably constructed of a polymeric material. Specifically, the buffer encasement 36 a preferably has a modulus of elasticity between approximately 5×10⁴ pounds per square inch and 1×10² pounds per square inch, and most preferably the modulus of elasticity is approximately 5×10³ pounds per square inch.

As best seen in FIG. 2, in accordance with the first embodiment, in an end elevation view thereof the optical module 30 a defines a generally parallelogram-like shape having rounded corners. More specifically, as illustrated in FIGS. 1 and 2, the optical module 30 a is in a generally rectangular configuration, which can also be characterized as a non-skewed configuration. For example, the optical module 30 a can be characterized as being in the generally rectangular configuration because, as best seen in FIG. 2, angles of approximately ninety degrees are defined between the vertical and horizontal segments of the buffer encasement 36 a.

As shown in FIG. 2, a height “H” cross-dimension is defined between opposite top and bottom sides of the optical module 30 a. In addition, a width “W” cross dimension that is perpendicular to the height H is defined between opposite right and left sides of the optical module 30 a. As will be discussed in greater detail below with reference to FIGS. 21 and 24-26, fiber optic cables having combinations of optical modules with different heights H and widths W are within the scope of the present invention.

Throughout this Detailed Description of the Invention section of this disclosure, items are described in the context of specific orientations, such as horizontal and vertical orientations. Those orientations are intended to provide a frame of reference to aid in the explanation of the present invention. The present invention can be described in the context of other orientations and is not limited to any specific orientation.

FIG. 3 is a perspective view of a representative optical fiber ribbon 34 of the optical module 30 a (FIGS. 1 and 2). In accordance with the present invention, one acceptable design for the optical fiber ribbons 34 is described in U.S. Pat. No. 4,900,126, which is incorporated herein by reference. More specifically, each optical fiber ribbon 34 extends longitudinally and includes a lateral array of conventional coated optical fibers 38 that transmit light. Whereas eight optical fibers 38 are shown in FIG. 3, it is generally preferred for there to be twelve or twenty-four optical fibers in each optical fiber ribbon 34, and it is within the scope of the present invention for each optical fiber ribbon to include a greater or lesser number of optical fibers.

Each optical fiber ribbon 34 further includes a solidified bonding material 40 that fills the interstices between the optical fibers 38, binds together the optical fibers, and extends to the outside boundary of the optical fiber ribbon 34. Each optical fiber ribbon 34 includes a pair of opposite edges 42, 44 that extend in the longitudinal direction, and a pair of opposite flat lateral surfaces 46, 48 that extend laterally between the edges 42, 44 and in the longitudinal direction. Referring back to FIG. 2, the generally rectangular configuration of the optical module 30 a is further characterized by the flat lateral surfaces 46, 48 (FIG. 3) of adjacent optical fiber ribbons 34 being substantially entirely contiguous.

The solidified bonding material 40 (FIG. 3) is acceptably a known ultraviolet-curable matrix material that includes a resin, a diluent and a photoinitiator. The resin may include a diethylenic-terminated resin synthesized from a reaction of hydroxy-terminated alkyl acrylate with the reaction product of a polyester of polyethyl polyol of molecular weight of 1,000 to 6,000 with an aliphatic or aromatic diisocyanate, or diethylenic-terminated resin synthesized from the reaction of glycidyl acrylate with a carboxylic-terminated polymer or polyether of molecular weight 1,000 to 6,000. The diluent may include monofunctional or multifunctional acrylic acid esters having a molecular weight of 100 to 1,000 or N-vinyl pyrrolidinone. For the photoinitiator, the composition may include ketonic compounds such as diethoxyacetophenone, acetophenone, benzophenone, benzoin, anthraquinone, and benzil dimethyl ketal. In a typical composition, the bonding matrix may include a resin (50-90%), diluents (5-40%), and a photoinitiator (1-10%). All percentages are by weight unless otherwise noted. Other bonding matrices may include a methacrylate, an ultraviolet-curing epoxide or an unsaturated polyester.

FIG. 4 is an isolated end elevation view of the ribbon stack 32 a of the optical module 30 a (FIGS. 1 and 2) in the generally rectangular configuration. That is, as illustrated in FIG. 4, the ribbon stack 32 a defines a generally rectangular shape and the flat lateral surfaces 46, 48 (FIG. 3) of adjacent optical fiber ribbons 34 are substantially entirely contiguous. In FIG. 4, the ribbon stack 32 a is illustrated as including four optical fiber ribbons 34, with each of the optical fiber ribbons containing eight optical fibers 38. In FIG. 4 only a few of the optical fibers 38 are specifically identified with their reference numeral. In accordance with the first embodiment, it is preferred for the ribbon stack 32 a to be in the form of a stack of twelve longitudinally extending optical fiber ribbons 34, with each optical fiber ribbon including a laterally extending one-dimensional array of twelve optical fibers 38. However, ribbon stacks 32 a containing different numbers of optical fiber ribbons 34 and optical fiber ribbons containing different numbers of optical fibers 38 are within the scope of the present invention.

In accordance with the first embodiment, the buffer encasement 36 a (FIGS. 1 and 2) may or may not be adhered to the ribbon stack 32 a. As best seen in FIG. 4, the ribbon stack 32 a has a top side 52, bottom side 54, right side 56, and left side 58. In accordance with an unadhered version of the first embodiment, which is most preferred, the buffer encasement 36 a is not adhered to the sides 52, 54, 56, 58 of the ribbon stack, so that the ribbon stack can move relative to the buffer encasement. As will be discussed in greater detail below, in accordance with this unadhered version, each of the sides 52, 54, 56, 58 is lubricated, in contact with the interior surface of the buffer encasement 36 a, and can move longitudinally relative to the buffer encasement. In contrast, in accordance with an adhered version of the first embodiment, the buffer encasement 36 a is adhered to the sides 52, 54, 56, 58 of the ribbon stack 32 a, so that the ribbon stack is restricted from moving relative to the buffer encasement.

As best seen in FIG. 4, in accordance with the first embodiment, interstices 50 that are arranged along the right and left sides 56, 58 of the ribbon stack 32 a are defined between the edges 42, 44 (FIG. 3) of adjacent optical fiber ribbons 34. As best seen in FIG. 2, in accordance with the illustrated version of the first embodiment, interstices 50 are not filled by the buffer encasement 36 a. In accordance with another version of the first embodiment, the interstices 50 are filled by the buffer encasement 36 a. Whether or not the interstices 50 are filled by the buffer encasement 36 a generally depends on the method by which, and the material from which, the buffer encasement is formed. As will be discussed in greater detail below, numerous methods for forming the buffer encasement 36 a are within the scope of the present invention.

As shown in FIG. 4, each optical fiber ribbon 34 defines approximately the same thickness T1. As best seen in FIG. 6, which is an isolated end elevation view of the buffer encasement 36 a of the optical module 30 a (FIGS. 1 and 2) in the rectangular configuration, the buffer encasement 36 a can be characterized as including four separate walls, each of which defines approximately the same thickness T2. In accordance with the first embodiment, the thickness T1 (FIG. 4) of each of the optical fiber ribbons 34 (FIGS. 1-3) is preferably at least approximately as great as the thickness T2 of the buffer encasement 36 a. Stated more specifically and differently, in accordance with the first embodiment in the entirety of the buffer encasement 36 a has a thickness of approximately T2 that is preferably not greater than the thickness T1 of each optical fiber ribbon 34. In accordance with the first embodiment, the thickness T1 of each optical fiber ribbon 34 is approximately 0.012 to 0.02 inches, or most preferably approximately 0.012 inches. In accordance with the first embodiment, the thickness T2 of the buffer encasement 36 a is approximately 0.003 to 0.012 inches, or more preferably approximately 0.007 to 0.012 inches, or most preferably approximately 0.008 to 0.009 inches.

FIG. 5 is an end elevation view of the optical module 30 a in a skewed configuration, in accordance with the first embodiment. For example, the optical module 30 a can be characterized as being in the skewed configuration because oblique angles are defined between the generally vertical and horizontal segments of the buffer encasement 36 a, and the lateral surfaces 46, 48 (FIG. 3) of adjacent optical fiber ribbons 34 are not entirely contiguous. That is, adjacent optical fiber ribbons 34 are at least partially laterally displaced from one another. Because the buffer encasement 36 a is constructed of a relatively thin flexible material, the optical fiber ribbons 34 are capable of sliding laterally relative to one another when oppositely oriented lateral forces are applied against the optical module 30 a, so that the optical module transitions from the generally rectangular configuration (FIGS. 1 and 2) to the skewed configuration. That is, the buffer encasement 36 a is constructed and arranged to be flexible enough to allow the optical fiber ribbons 34 to slide laterally relative to one another so that, in an end elevation view thereof, the stack can transition from an approximately rectangular arrangement to the skewed configuration. The buffer encasement 36 a is further constructed and arranged to be rigid enough to maintain the stack of optical fiber ribbons 34 in a stacked configuration when the optical module 30 a is transitioned from the generally rectangular configuration to the skewed configuration. Further, the buffer encasement 36 a is constructed and arranged so that the optical module 30 a is biased toward the generally rectangular configuration.

In accordance with the illustrated version of the first embodiment, the ability of the optical module 30 a to be readily transitioned between the generally rectangular configuration (FIGS. 1 and 2) and the skewed configuration (FIG. 5) is enhanced by virtue of the interstices 50 (FIG. 4) defined between the edges 42, 44 (FIG. 3) of adjacent optical fiber ribbons 34 not being filled by the buffer encasement 36 a. Further, in accordance with the unadhered version of the first embodiment, a coating of lubricant (not shown), such as oil or the like, as will be discussed in greater detail below, is upon the edges 42, 44 and lateral surfaces 46, 48 (FIG. 3) of each of the optical fiber ribbons 34. The lubricant enhances the ability of the optical fiber ribbons 34 to be moved laterally and longitudinally relative to one another and relative to the buffer encasement 36 a. Therefore, the lubricant enhances the ability of the optical module 30 a to be transitioned between the generally rectangular configuration and the skewed configuration.

As best seen in FIG. 6, the buffer encasement 36 a includes an interior surface 60 a and an exterior surface 62 a. The interior surface 60 a extends around and defines a longitudinally extending passage 64. In accordance with the first embodiment, in both the generally rectangular configuration (FIGS. 1 and 2) and the skewed configuration (FIG. 5), the interior surface 60 a closely bounds the periphery of the ribbon stack 32 a (FIGS. 1, 2, and 3) and the exterior surface 62 a closely bounds the interior surface. The close bounding of the interior and exterior surfaces 60 a, 60 b provides for efficient packaging of multiple of the optical modules 30 a (FIGS. 1, 2, and 5), as will be discussed in greater detail below. More specifically, in an end elevation view of the optical module 30 a during both the generally rectangular configuration and the skewed configuration, the interior surface 60 a defines a shape that is substantially similar to the shape defined by the periphery of the ribbon stack 32 a (FIGS. 1, 2, 4, and 5), with substantially the only difference between the shapes being that the interstices 50 (FIG. 4) are not filled by the buffer encasement 36 a. In addition, in the end elevation view of the optical module 30 a during both the generally rectangular configuration and the skewed configuration, the exterior surface 62 a also defines a shape that is substantially similar to the shape defined by the periphery of the ribbon stack 32 a, with substantially the only difference between the shapes being that the interstices 50 are not filled by the buffer encasement 36 a. In both the generally rectangular configuration and the skewed configuration, in the end elevation view of the optical module 30 a, the periphery of the ribbon stack 32 a bounds a first area and the interior surface of the buffer encasement 36 a bounds a second area, and the first and second areas are approximately equal.

In accordance with a first version of the first embodiment, the buffer encasement 36 a is homogenous, meaning that all portions of the buffer encasement have approximately the same properties, such as hardness and modulus of elasticity. As best understood with reference to FIG. 6, in accordance with a second version of the first embodiment, the buffer encasement 36 a has an inner portion 68 a and an outer portion 70 a that are preferably not physically separate from one another but that have different properties, such as hardness and modulus of elasticity. Although there is not necessarily a clearly visible distinction between the inner and outer portions 68 a, 70 a with the naked eye and the transition between the inner and outer portions may be gradual, for purposes of explanation a separation line 66 is illustrated by broken lines in FIG. 6 to demonstrate a boundary between the inner and outer portions. In accordance with the second version of the first embodiment, the outer portion 70 a has a hardness and modulus of elasticity that are greater than the hardness and modulus of elasticity of the inner portion 68 a. More specifically, in accordance with the second version of the first embodiment, the inner portion 68 a of the buffer encasement 36 a preferably has a modulus of elasticity between approximately 2×10⁴ pounds per square inch and 1×10² pounds per square inch, and most preferably the modulus of elasticity of the inner portion is approximately 1×10³ pounds per square inch. In contrast, in accordance with the second version of the first embodiment, the outer portion 70 a of the buffer encasement 36 a preferably has a modulus of elasticity between approximately 6×10⁵ pounds per square inch and 2×10⁴ pounds per square inch, and most preferably the modulus of elasticity of the outer portion is approximately 2×10⁵ pounds per square.

In accordance with the first embodiment, it is preferred for the optical fibers 38 and the optical fiber ribbons 34 to be conventionally color-coded or marked with identifying indicia, or the like, for identification purposes. It is preferred for the buffer encasement 36 a to be clear so that the identifying colors or markings of the optical fiber ribbons 34 and/or optical fibers 38 can be seen through the buffer encasement. Alternatively or in addition, different buffer encasements 36 a are color-coded or marked with identifying indicia, or the like, for identification purposes.

In accordance with a version of the first embodiment, the buffer encasement 36 a can be easily tom so that the buffer encasement can be easily removed from the ribbon stack 32 a. In accordance with one example of this easily tom version, the buffer encasement 36 a has an ultimate tensile strength of less than approximately 2×10³ pounds per square inch and a thickness T2 (FIG. 6) of less than approximately 0.020 inches. In accordance with this example of the easily tom version, the buffer encasement 36 a is acceptably constructed of low-density polyethylene, or the like.

In accordance with another example of the easily tom version, the buffer encasement 36 a is easily tearable because it is constructed of a polymeric material that contains one or more fillers, such as inorganic fillers, that reduce the elongation and/or tensile strength of the polymeric material. Preferably this easily tearable buffer encasement has a tensile strength of less than approximately 2,000 pounds per square inch, an elongation of less than approximately 400 percent, and most preferably less than approximately 200 percent. In accordance with this example, suitable base resins or polymers include polyethylene, ethylene-vinyl acetate, ethylene-acrylic acid, or the like. In accordance with this example, suitable fillers include talc, calcium carbonate, aluminum trihydrate, or the like.

Second Embodiment

FIG. 7 is a perspective view of an optical module 30 b in accordance with a second embodiment of the present invention. The optical module 30 b of the second embodiment is identical to the optical module 30 a (FIGS. 1, 2, and 5) of the first embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

In accordance with the second embodiment, the ribbon stack 32 b of the optical module 30 b is longitudinally twisted when its buffer encasement 36 b is formed therearound, and the buffer encasement 36 b is sufficiently rigid to hold the ribbon stack 32 b in its twisted configuration. In addition, as described above for the first embodiment, the buffer encasement 36 a of the second embodiment is relatively thin and conforms closely to the exterior surface of the ribbon stack 32 a. As a result, the longitudinally extending four corners 71 of the buffer encasement 36 a are arranged so as to define a longitudinal twist that corresponds to the twist of the ribbon stack 32 b, as is shown in FIG. 7. That is, the exterior surface 62 b of the buffer encasement 36 b defines ridge-like comers 71, which can be characterized as ridges, that define a lay length that corresponds to the lay length of the twisted ribbon stack 32 b. The comers 71 are preferably somewhat rounded.

The optical module 30 b can have a continuous helical twist or an S-Z twist. More specifically, the ribbon stack 32 b can be longitudinally twisted in the same direction for the entire length of the buffer encasement 36 b to provide the continuous helical twist. In contrast, it is preferred for the longitudinal twisting of the ribbon stack 32 b to be periodically reversed, so that the optical module 30 b has what is referred to by those of ordinary skill in the art as an S-Z twist. In this regard, along a first section of the buffer encasement 36 b the ribbon stack 32 b is longitudinally twisted in a first direction to define a lay length, and the ribbon stack is longitudinally twisted in an opposite second direction along a contiguous second section of the buffer encasement to again define the lay length. The lay length is the longitudinal distance in which the ribbon stack 32 b makes a complete revolution. That alternating twisting pattern is repeated along the entire length of the ribbon stack 30 b. In accordance with the second embodiment, the lay length of the S-Z twist is preferably in the range of approximately twelve to thirty-six inches, and most preferably the lay length is approximately twenty-four inches.

Third Embodiment

FIG. 8 is an end elevation view of an optical module 30 c in accordance with a third embodiment of the present invention. The optical module 30 c of the third embodiment is identical to the optical module 30 a (FIGS. 1, 2, and 5) of the first embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

In accordance with the third embodiment, the buffer encasement 36 c defines a longitudinally extending weakened portion. The weakened portion preferably extends for the length of the optical module 30 c and is preferably in the form of a longitudinally extending frangible portion 72. Whereas the frangible portion 72 is shown in the form of a trough-like cutout, the frangible portion can be in the form of a series of perforations or other voids or means that weaken the buffer encasement 36 c. The buffer encasement 36 c can be manually longitudinally torn along the frangible portion 72 more easily than the buffer encasement can be torn at other locations. Nonetheless, the frangible portion 72 is preferably constructed and arranged so that it does not tear inadvertently.

The frangible portion 72 is longitudinally torn to provide access to the optical fiber ribbons 34 contained within the buffer encasement 36 c. More specifically, by tearing the buffer encasement 36 c along the frangible portion 72, opposite longitudinally extending torn edges 74, 76, which are illustrated by broken lines in FIG. 8, are formed. The torn edges 74, 76 are manually lifted away from the optical fiber ribbons 34 contained by the buffer encasement 36 c so that a longitudinally extending opening 78 c is defined between the torn edges, as is illustrated by broken lines in FIG. 8. The optical fiber ribbons 34 contained by the buffer encasement 36 c can be accessed through the opening 78 c. In accordance with an alternative embodiment of the present invention, the buffer encasement 36 c is constructed of a material that can be easily torn so that the buffer encasement can be readily manually longitudinally torn without including a frangible portion 72.

Fourth Embodiment

FIG. 9 is an end elevation view an optical module 30 d in accordance with a fourth embodiment of the present invention. The optical module 30 d of the fourth embodiment is identical to the optical module 30 a (FIGS. 1, 2, and 5) of the first embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

In accordance with the fourth embodiment, the buffer encasement 36 d is preferably a longitudinally extending piece of polymeric film or tape. The tape preferably cannot be penetrated by water and/or may be coated with a conventional powder that absorbs water, or the like. The buffer encasement 36 d includes opposite longitudinally extending edges 80, 82 that overlap one another so the optical fiber ribbons 34 are enclosed within the buffer encasement.

The surfaces of the edges 80, 82 that are overlapping and facing one another are preferably held together by a conventional adhesive so that those edges remain in their overlapping arrangement. In accordance with the unadhered version of the fourth embodiment, the adhesive does not cover the entire interior surface of the buffer encasement 36 d so the optical fiber ribbons 34 contained by the buffer encasement can move relative to one another and relative to the buffer encasement. In accordance with the adhered version of the fourth embodiment, the entire interior surface of the buffer encasement 36 d is be covered by the adhesive so that movement of the optical fiber ribbons 34 relative to one another as well as relative to the buffer encasement is impeded.

In accordance with the fourth embodiment, when access to the optical fiber ribbons 34 within the buffer encasement 36 c is desired, the edges 80, 82 are manually separated to provide access to the optical fiber ribbons within the buffer encasement. More specifically, the separated edges 80, 82 are lifted away from the optical fiber ribbons 34 contained by the buffer encasement 36 d so that a longitudinally extending opening 78 d is defined between the edges, as is illustrated by broken lines in FIG. 9. The optical fiber ribbons 34 contained by the buffer encasement 36 d can be accessed through the opening 78 d. In addition, the edges 80, 82 can be returned to their original configurations to again fully enclose the optical fiber ribbons 34, if desired.

In accordance with an alternative embodiment of the present invention, the polymeric tape or sheet from which the buffer encasement 36 d is constructed is wrapped helically around the optical fiber ribbons 34 to form the buffer encasement, rather than being longitudinally applied to the optical fiber ribbons.

Fifth Embodiment

FIGS. 10 and 11 are perspective and end elevation views, respectively, of an optical module 30 e in accordance with a fifth embodiment of the present invention. The optical module 30 e of the fifth embodiment is identical to the optical module 30 a (FIGS. 1, 2, and 5) of the second version of the first embodiment, which is discussed above with reference to FIG. 6, except for noted variations and variations apparent to those of ordinary skill in the art.

In accordance with the fifth embodiment, the buffer encasement 36 e has multiple plies. More specifically, the inner and outer portions 68 e, 70 e are separate plies. The inner portion 68 e includes an outer surface 86 e and the outer portion 70 e includes an inner surface 88 e. In accordance with the fifth embodiment, the entire inner surface 88 e extends around and is in contact with the entire outer surface 86 e for the entire length of the optical module 30 e. In accordance with a first version of the fifth embodiment, the inner and outer portions 68 e, 70 e are coaxial thermoplastic coextrusions. In accordance with a second version of the fifth embodiment, the inner portion 68 e is like the tapes or films described above with reference to the fourth embodiment, and the outer portion 70 e is a polymeric extrusion, with the thickness of the multi-ply buffer encasement 36 e being identical to the thickness T2 (FIG. 6) of the buffer encasement 36 a (FIGS. 1, 2, and 5) of the first embodiment. Alternatively the thickness of the multi-ply buffer encasement 36 e is greater than the thickness of the buffer encasement 36 a of the first embodiment. A third version of the fifth embodiment is identical to the second version of the fifth embodiment, except that both the inner portion 68 e and the outer portion 70 e are like the tapes or films described above with reference to the fourth embodiment.

Sixth Embodiment

FIGS. 12 and 13 are perspective and end elevation views, respectively, of an optical module 30 f in accordance with a sixth embodiment of the present invention. The optical module 30 f of the sixth embodiment is identical to the optical module 30 a (FIGS. 1, 2, and 5) of the first embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

As best seen in FIG. 13, in accordance with the illustrated version of the sixth embodiment, the interstices 50 (FIG. 4) defined between the edges 42, 44 (FIG. 3) of the optical fiber ribbons 34′ are filled by portions of the buffer encasement 36 f. In addition, the buffer encasement 36 f includes thickened portions 90 at the opposite four corners thereof. The thickened portions 90 preferably define bulbous-like shapes that cushion the optical fibers positioned at the opposite four comers of the ribbon stack 32 f Except for the thickened portions 90, the thickness of the buffer encasement 36 f is identical to the thickness T2 (FIG. 6) of the buffer encasement 36 a (FIGS. 1, 2, 5, and 6) of the first embodiment. Accordingly, a vast majority of the buffer encasement 36 f has a thickness defined between the interior and exterior surfaces thereof that is not greater than the thickness of each of the optical fiber ribbons 34′ contained by the buffer encasement 36 f.

Seventh Embodiment

FIG. 14 is an end elevation view of an optical module 30 g in accordance with a seventh embodiment of the present invention. The optical module 30 g of the seventh embodiment is identical to the optical module 30 a (FIGS. 1, 2, and 5) of the first embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

The optical module 30 g is illustrated in the non-skewed configuration in FIG. 14 and therefore can be characterized as including a generally round ribbon stack 32 g and a round buffer encasement 36 g. In contrast, the ribbon stack 32 g and the buffer encasement 36 g may be oblong in an end elevation view thereof while the optical module 30 g is in the skewed configuration. The optical fiber ribbons 34, 34′, 34″, 34′″, 34″″ of the ribbon stack 32 g have different widths, and some of the optical fiber ribbons are in a side-by-side arrangement. In addition, the thickness of the buffer encasement 36 g is measured in the direction of radii that radiate from the center of the optical module 30 g in an end elevation view thereof. Whereas that thickness varies with the angle of the radii, the average thickness of the buffer encasement 36 g corresponds to the thickness T2 (FIG. 6) of the buffer encasement 62 a (FIGS. 1,2, 5, and 6) of the first embodiment. That is, a majority of the buffer encasement 36 g has a thickness defined between the interior and exterior surfaces thereof that is not greater than the thickness (for example see the thickness T1 illustrated in FIG. 4) of each of the optical fiber ribbons 34, 34′, 34″, 34′″, 34″″ contained by the buffer encasement 36 g.

Methods of Manufacturing Optical Modules

FIG. 15 diagrammatically illustrates an assembly of manufacturing equipment 92 that is capable of acceptably manufacturing optical modules, such as the above-discussed optical modules 30 a, 30 b, 30 c, 30 d, 30 e, 30 f, 30 g of the present invention. For the purpose of describing methods of operation of the assembly of manufacturing equipment 92, the above-described optical modules, ribbon stacks, and buffer encasements are referred to generically as optical module 30, ribbon stack 32, and buffer encasement 36. The assembly of manufacturing equipment 92 operates such that the optical fiber ribbons 34 and the formed ribbon stack 32, buffer encasement 36, and optical module 30 are continuously longitudinally advanced.

Upstream Guiding Mechanism

As seen in FIG. 15, separate optical fiber ribbons 34 are drawn in parallel into an upstream guiding mechanism 94. Whereas only four optical fiber ribbons 34 are illustrated in FIG. 15, it is within the scope of the present invention for more and less than four optical fiber ribbons to be drawn into the assembly of manufacturing equipment 92. The process of feeding the optical fiber ribbons 34 to the upstream guiding mechanism 94 preferably includes conventionally dispensing previously manufactured optical fiber ribbons 34, such as dispensing the optical fiber ribbons from reels that are positioned upstream from the upstream guiding mechanism.

In accordance with one example of the present invention, the guiding mechanism 94 includes multiple rollers, or the like, that defined nips through which the optical fiber ribbons 34 are drawn for generally aligning the optical fiber ribbons with one another and maintaining spaces between the optical fiber ribbons. It is conventional to draw optical fiber ribbons into a parallel arrangement, so the operations of the upstream guiding mechanism 94 should be understood by those of ordinary skill in the art.

Lubricating Mechanism

As illustrated in FIG. 15, the aligned optical fiber ribbons 34 are drawn from the upstream guiding mechanism 94 to a lubricating mechanism 96. The lubricating mechanism 96 applies lubricant to the edges 42, 44 (FIG. 3) and the lateral surfaces 46, 48 (FIG. 3) of each of the optical fiber ribbons 34. The lubricant can be acceptably applied to the optical fiber ribbons 34 by any of numerous conventional coating techniques. For example, liquid lubricant can be applied to the optical fiber ribbons 34 by a spraying assembly including pump(s) that force liquid lubricant to flow from a reservoir, through piping, and out of spray nozzles that direct the lubricant onto the optical fiber ribbons 34. An example of an assembly for applying lubricant to optical fiber ribbons is disclosed in U.S. patent application Ser. No. 09/179,721, which is incorporated herein by reference. In addition, the optical fiber ribbons 34 can be drawn through a bath of the lubricant, or drawn between absorbent rollers that are saturated with the lubricant. Alternatively, powder-type lubricants can be sprinkled and blown onto the optical fiber ribbons 34.

It is preferred for the applied lubricant not to adversely interact with the optical fiber ribbons 34 or the buffer encasement 36 formed around the optical fiber ribbons. For example, it is preferred for the lubricant not to cause the buffer encasement 36 to swell. For example, in accordance with some embodiments of the present invention “E”-type hydrocarbon oils are used when the buffer encasement 36 is constructed of a low density polyethylene material. Specifically, “E”-type hydrocarbon oil comprises 22.5% by weight of SHF-402 polyalphaolefin oil; 75.5% by weight of SHF-82 polyalphaolefin oil; and 2% by weight of IRGANOX® 1076 antioxidant. These polyalphaolefin oils are commercially available from Mobil Chemical Company, and the antioxidant (stabilizer) is commercially available from the Ciba-Geigy Company. This oil has a viscosity between 54 and 82 centistrokes at 40° C., and a viscosity between 8 and 12 centistrokes at 100° C. when measured in accordance with the method of ASTM D-445. These oils were selected to have a kinematic viscosity that is less than 4000 centistrokes at 100° C.

In accordance with other embodiments of the present invention a more polar oil, such as glycol, is used when the buffer encasement 36 is constructed of ethylene-vinyl acetate copolymer. It is also preferred for the lubricant that is applied to the optical fiber ribbons 34 to be water resistant or contain a water absorbent powder, or the like. For a majority of the embodiments of the present invention, including the second embodiment, a preferred lubricant is stabilized polyalphaolefin oil, or the like. Other suitable lubricants include glycol, silicone oils, or the like.

It is also within the scope of the present invention for the assembly of manufacturing equipment 92 not to include the lubricating mechanism 96. For example, it is within the scope of the present invention for the optical fiber ribbons 34 of an optical module 30 to not be lubricated, such as for the unadhered versions of the optical module discussed above with reference to the first embodiment.

Downstream Guiding Mechanism

As illustrated in FIG. 15, the optical fiber ribbons 34 are drawn from the lubricating mechanism 96 to a downstream guiding mechanism 98. The downstream guiding mechanism 98 includes multiple rollers that guide the optical fiber ribbons 34 so that the optical fiber ribbons are formed into a ribbon stack 32. It is conventional to arrange optical fiber ribbons 34 into a ribbon stack 32, so the operations of the downstream guiding mechanism 98 should be understood by those of ordinary skill in the art.

Twisting Mechanism

The assembly of manufacturing equipment 92 is illustrated as further including a twisting mechanism 99. In accordance with those embodiments of the present invention in which the ribbon stack 32 is twisted, the ribbon stack 32 is drawn from the downstream guiding mechanism 98 to the twisting mechanism 99. The twisting mechanism 99 is operative to impart either a continuous helical twist in the ribbon stack 32 or an S-Z twist, as described above with reference to the second embodiment of the present invention.

It is preferred, when practicable, for many of the optical modules 30 of the present invention to be constructed so that their ribbon stacks 32 are S-Z twisted. For example, in accordance with alternative embodiments of the present invention, optical modules 30 similar to the optical modules 30 a (FIGS. 1, 2, and 5), 30 c (FIG. 8), 30 d (FIG. 9), and 30 e (FIGS. 10 and 11), and discussed variants thereof, have twisted ribbon stacks 32.

It is conventional to longitudinally twist ribbon stacks 32, so the operations of the twisting mechanism 99 should be understood by those of ordinary skill in the art. An acceptable example of a twisting mechanism is disclosed in U.S. patent application Ser. No. 09/179,721, which has been incorporated herein by reference. In accordance with embodiments of the present invention in which the ribbon stack 32 is twisted, the ribbon stack is drawn from the twisting mechanism 99 to the encasing mechanism 100.

In accordance with some of the embodiments of the present invention, the ribbon stack 32 is not twisted, in which case the twisting mechanism 99 is bypassed or omitted from the assembly of manufacturing equipment 92. That is, in accordance with embodiments of the present invention in which the ribbon stack 32 is not twisted, the ribbon stack is drawn from the downstream guiding mechanism 98 to an encasing mechanism 100.

Encasing Mechanism

The encasing mechanism 100 forms the buffer encasement 36 around the ribbon stack 32 to form the optical module 30. Multiple variations of the encasing mechanism 100 are within the scope of the present invention, and examples of them will be briefly described, followed by a more detailed discussion of each. In accordance with a first method of the present invention, the encasing mechanism 100 applies a polymeric tape or film to the ribbon stack 32 to form the buffer encasement 36. In accordance with a second method of the present invention, the encasing mechanism 100 extrudes thermoplastic material around the ribbon stack 32 to form the buffer encasement 36. In accordance with a third method of the present invention, the encasing mechanism 100 applies an ultraviolet-curable material onto the ribbon stack 32 and cures that material to form the buffer encasement 36. In accordance with a fourth method of the present invention, the encasing mechanism 100 performs the above operations in various combinations and subcombinations to provide composite buffer encasements 36.

First Method: In accordance with the first method of the present invention, the buffer encasement 36 is formed by way of the encasing mechanism 100 applying a longitudinally extending polymeric tape or film to the ribbon stack 32, or helically wrapping the tape or film around the ribbon stack to produce an optical module 30. It is conventional in the construction of fiber optic cables to apply a longitudinally extending tape to a longitudinally advancing member, and to helically wrap tape around a longitudinally advancing member, so those of ordinary skill in the art should be able to select a suitable encasing mechanism 100 for carrying out the first method.

Optical modules 30 constructed in accordance with the first method include those described above with reference to the fourth embodiment and variations thereof. It is also within the scope of the present invention for other optical modules 30 to be constructed in accordance with the first method.

In accordance with the first method, the tapes or films from which the buffer encasement 36 is constructed are acceptably constructed from thermoplastic materials, or more specifically polyolefin materials, or more specifically polyethylene. In accordance with the fourth embodiment discussed above, a particularly suitable tape is conventional water-blocking tape with conventional nonwoven polyester backing.

Second Method: In accordance with the second method of the present invention, the encasing mechanism 100 includes one or more extruders that extrude the buffer encasement 36 over the ribbon stack 32. It is conventional in the construction of fiber optic cables to utilize an extruder to extrude a thermoplastic material onto a longitudinally advancing member, so those of ordinary skill in the art should be able to select a suitable encasing mechanism 100 for carrying out the second method.

In accordance with the second method, the material being extruded is acceptably a thermoplastic material, or more specifically a polyolefin material, or more specifically polyethylene. Further, in accordance with the second method, the extrusion(s) may be sufficiently solidified through exposure to the ambient air. Alternatively or in addition, the encasing mechanism 100 can include cooling mechanism(s) that aid in the cooling and solidification of the extrusion(s). Acceptable cooling mechanisms include water baths, or the like.

In accordance with a first version of the second method, the encasing mechanism 100 extrudes a thermoplastic extrusion around the ribbon stack 32, and that extrusion solidifies to form the buffer encasement 36. More specifically, the initially formed extrusion has internal dimensions that are larger than the external dimensions of the ribbon stack 32, and as the extrusion solidifies the extrusion is “drawn down” to the ribbon stack 32 to form the buffer encasement 36. As a result of the drawing down, the internal dimensions of the buffer encasement 36 are approximately equal to the external dimensions of the ribbon stack 32. For example, the optical module 30 a (FIG. 1, 2 and 5) of the first version of the first embodiment and the optical modules 30 b, 30 c of the second and third embodiments, respectively, can be constructed in accordance with the first version of the second method. In accordance with the first version of the second method, a particularly suitable material for extruding to form the buffer encasements 36, and the material that is preferably used to construct the buffer encasement 36 b (FIG. 7) of the second embodiment, is low-density polyethylene, or the like.

Second and third versions of the second method are similar to the first version of the second method, except in accordance with the second and third versions the encasing mechanism 100 forms thermoplastic coextrusions around the ribbon stack 32. In accordance with the second version of the second method, the facing surfaces of the coextrusions partially blend together before solidifying, for example to produce the nonhomogenous buffer encasement 36 a (FIG. 6) of the second version of the first embodiment. In accordance with the second version of the second method, a preferred material for extruding to form the inner portion 68 a (FIG. 6) of the buffer encasement 36 a is very low density polyethylene-vinyl acetate, ethylene-acrylic acid, or the like. In accordance with the second version of the second method, a preferred material for extruding to form the outer portion 70 a (FIG. 6) of the buffer encasement 36 a is medium or high density polyethylene, or the like.

In accordance with the third version of the second method, the coextrusions do not partially blend together before solidifying, for example to produce the buffer encasement 36 e (FIGS. 10 and 11) of the fifth embodiment. In accordance with the third version of the second embodiment, a preferred material for extruding to form the inner portion 68 e (FIGS. 10 and 11) of the buffer encasement 36 e is very low density polyethylene, ethylene-vinyl acetate, ethylene-acrylic acid, or the like. In accordance with the third version of the second embodiment, a preferred material for extruding to form the outer portion 70 e (FIGS. 10 and 11) of the buffer encasement 36 e is impact modified polypropylene (propylene-ethylene copolymer), or the like.

Third Method: In accordance with the third method of the present invention, the encasing mechanism 100 applies an uncured ultraviolet-curable material onto and around the ribbon stack 32 and thereafter cures the ultraviolet-curable material to form the buffer encasement 36 around the ribbon stack. The ultraviolet-curable material is cured by exposure to ultraviolet radiation. As mentioned above, it is conventional to use ultraviolet-curable materials is the construction of optical fiber ribbons 34, so those of ordinary skill in the art should be able to select a suitable encasing mechanism 100 for carrying out the third method.

In accordance with the third method, the uncured ultraviolet-curable material can be applied to the ribbon stack 32 through the use of several different techniques. For example, the uncured ultraviolet-curable material can be extruded onto the ribbon stack 32, sprayed onto the ribbon stack, or the ribbon stack can be drawn through a bath of the uncured ultraviolet-curable material. Thereafter, the uncured ultraviolet-curable material on the ribbon stack 32 is cured by exposure to ultraviolet radiation.

Optical modules 30 constructed in accordance with the third method include those described above with reference to the sixth and seventh embodiments. For example, when constructing the optical module 30 f (FIGS. 12 and 13) of the sixth embodiment, preferably a thick ultraviolet-curable material is extruded onto the ribbon stack 32 f (FIGS. 12 and 13), and the die that is used for the extruding is constructed and arranged to define the shape of the resulting buffer encasement 36 f (FIGS. 12 and 13).

In accordance with the third method, buffer encasements 36 having inner and outer portions, such as inner and outer portions 68 a, 70 a (FIG. 6), with different properties can be produced by controlling the application of the ultraviolet radiation to the uncured ultraviolet-curable material that has been applied to the ribbon stack 32. For example, a homogenous ultraviolet-curable gel can be applied to a ribbon stack 32 and then the duration and intensity of the ultraviolet radiation imparted on the applied ultraviolet-curable material is controlled so the resulting buffer encasement 36 has an inner portion and an outer portion, such as inner and outer portions 68 a, 70 a, having different hardness and modulus of elasticity. For example, it is preferred for the inner portion to be softer and have a lower modulus of elasticity, and for the outer portion to be harder and have a higher modules of elasticity, as described above with reference to the second version of the first embodiment. That is, the forming of the buffer encasement 36 is carried out by coating the stack of optical fiber ribbons 34 with the ultraviolet-curable material and thereafter exposing the ultraviolet-curable material to ultraviolet radiation for a predetermined period of time selected so that on a per unit basis more curing, such as polymerization, occurs in the outer portion 70 a than the inner portion 68 a.

A suitable ultraviolet-curable material is that which is described above as being used in the formation of the optical fiber ribbons 34. Other suitable ultraviolet-curable materials include acrylate materials that are polymerized when exposed to ultraviolet radiation to create polyacrylate.

Fourth Method: In accordance with the fourth method of the present invention, the first, second, and third methods are combined and/or varied to produce other optical modules 30. For example, in accordance with the second version of the fifth embodiment, the inner portion 68 e (FIGS. 10 and 11) is constructed of a tape or film of polymeric material that blocks water, and the outer portion 70 e (FIGS. 10 and 11) is an extrusion of polymeric material.

Weakening Mechanism

In accordance with embodiments of the present invention in which the buffer encasement 36 includes a frangible portion 72 (FIG. 8), or the like, the optical module is drawn from the encasing mechanism 100 to a weakening mechanism 101. The weakening mechanism 101 forms a longitudinally extending frangible portion, such as the illustrated frangible portion 72, in the buffer encasement 36. Suitable frangible portions can be formed through the use of a wide variety of devices, such as cutting, scoring, or piercing devices, or the like.

In accordance with the third embodiment, the weakening mechanism 101 is preferably a machine that generates a laser beam that is used to cut the buffer encasement 36 c (FIG. 8) to form the frangible portion 72 (FIG. 8). Cutting machines that form precise cuts by means of a laser are conventional and readily available

Storing Mechanism

As illustrated in FIG. 15, the completely manufactured optical module 30 is drawn to a conventional storing mechanism 102. A suitable storing mechanism can include a reel that the manufactured optical module 30 is drawn onto and wrapped around. Optical modules 30 that have been longitudinally twisted, such as the optical module 30 b (FIG. 7) and round optical modules, such as the optical module 30 g (FIG. 14), are particularly well suited for being wound onto reels. Alternatively, the storing mechanism 102 can include barrels that the manufactured optical modules 30 are continuously drawn toward and dropped into.

Irrespective of the manner in which an optical module 30 is stored, it is preferred for the opposite ends of the optical module to be readily available so that the optical integrity of the optical module can be tested prior to incorporating the optical module into a fiber optic cable. This is particularly advantageous with respect to fiber optic cables that include multiple optical modules 30 in parallel.

Fiber Optic Cables

FIGS. 16-21 and 24-26 illustrates fiber optic cables in accordance with embodiments of the present invention. For the purpose of describing the fiber optic cables, the above-described optical modules 30 a, 30 b, 30 c, 30 d, 30 e, 30 f, 30 g of the present invention are referred to generically as optical modules 30, because it is within the scope of the present invention for each of the below-described fiber optic cables, and/or variations thereof, to be constructed with each of the above-described optical modules and combinations thereof, with exceptions being noted or apparent to those of ordinary skill in the art. Likewise, the above-described ribbon stacks and buffer encasements are respectively referred to generically as ribbon stacks 32 and buffer encasements 36.

Eighth Embodiment

FIG. 16 is a schematic end elevation view of a fiber optic cable 108 a in accordance with an eighth embodiment of the present invention. The fiber optic cable 108 a includes a centrally located and longitudinally extending optical module 30 that is preferably surrounded by a conventional, longitudinally extending piece of water-blocking tape 110. A conventional outer jacket of polymeric material 112 a extends around the water-blocking tape 110 and longitudinally extending outer strength members 114 a are embedded in the outer jacket. The space between the water-blocking tape 110 and the optical module 30, as well as the space between the outer jacket 112 a and the water-blocking tape, can be filled with a conventional filler material, such as a thixotropic gel. It is preferred for each of the fiber optic cables of the present invention not to include any filler materials, such as thixotropic gels, but it is also within the scope of the present invention for each of the fiber optic cables of the present invention to include filler materials, such as thixotropic gels. In accordance with the present invention, it is preferred for the buffer encasements 36 to sufficiently protect the ribbon stacks 32 so that filler materials are not required.

The outer jacket 112 a can incorporate more than two outer strength members 114 a. In addition, the outer jacket 112 a can be constructed of a metallic material or a dialectric material. Also, the fiber optic cable 108 a can further include metal armor that extends around and further protects the optical module(s) 30.

Ninth Embodiment

FIG. 17 is a schematic end elevation view of a fiber optic cable 108 b in accordance with a ninth embodiment of the present invention. The fiber optic cable 108 b of the ninth embodiment is identical to the fiber optic cable 108 a (FIG. 16) of the eighth embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

The fiber optic cable 108 b of the ninth embodiment includes multiple ribbon stacks 32 (for example see FIG. 4) that are in a symmetrical stacked arrangement that is generally uniform along the length of the fiber optic cable and results in dense packaging of optical fibers. The multiple ribbon stacks 32 are preferably components of multiple optical modules 30. The optical modules 30 are preferably not twisted, are preferably generally polygonal, and are preferably maintained in the stacked symmetrical arrangement along the entire length of the fiber optic cable 108 b. Although not shown in FIG. 17, the group of optical modules 30 can be collectively encircled by water-blocking tape (for example, see the water-blocking tape 110 (FIG. 16)). Because the optical modules 30 are discreet units, operative optical modules can be readily salvaged from the fiber optic cable 108 b if the fiber optic cable becomes damaged.

Tenth Embodiment

FIG. 18 is a schematic end elevation view of a fiber optic cable 108 c in accordance with a tenth embodiment of the present invention. The fiber optic cable 108 c of the tenth embodiment is identical to the fiber optic cable 108 b (FIG. 17) of the ninth embodiment, except for noted variations and variations apparent to one of ordinary skill in the art.

The fiber optic cable 108 c of the tenth embodiment includes multiple ribbon stacks 32 (for example see FIG. 4) that are stacked, but they are not in a completely symmetrical arrangement. The multiple ribbons stacks 32 are preferably components of multiple optical modules 30. The optical modules 30 are preferably not twisted and are preferably generally polygonal and maintained in the stacked arrangement along the entire length of the fiber optic cable 108 c.

Eleventh Embodiment

FIG. 19 is a schematic end elevation view of a fiber optic cable 108 d in accordance with an eleventh embodiment of the present invention. The fiber optic cable 108 d of the eleventh embodiment is identical to the fiber optic cable 108 a (FIG. 16) of the eighth embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

The fiber optic cable 108 c includes multiple ribbon stacks 32 (for example see FIG. 4) that are laterally spaced apart from one another in a somewhat random arrangement so the optical modules are not in a symmetrical stacked configuration. The multiple ribbons stacks 32 are preferably components of multiple optical modules 30. Whereas the fiber optic cable 108 d of the eleventh embodiment is illustrated as including a central strength member 116 in addition to the outer strength members 114 a, it is preferred for the fiber optical cable 108 d to have either the central strength member or the outer strength members, but not both. Although not shown, the group of optical modules 30 can be collectively encircled by water-blocking tape (for example, see the water-blocking tape 110 (FIG. 16)).

Twelfth Embodiment

FIG. 20 is a schematic end elevation view of a fiber optic cable 108 e in accordance with a twelfth embodiment of the present invention. The fiber optic cable 108 e of the twelfth embodiment is identical to the fiber optic cable 108 d (FIG. 19) of the eleventh embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

In accordance with the twelfth embodiment, the multiple ribbon stacks 32 (for example see FIG. 4) are tightly packed into the outer jacket 112 e. The multiple ribbons stacks 32 are preferably components of multiple optical modules 30. As one example, the optical modules 30 can be characterized as being in a somewhat random arrangement such that they are not in a symmetrical stacked configuration. In accordance with the twelfth embodiment, the enclosing of the optical modules 30 in the longitudinally extending passage defined by the outer jacket 112 e causes lateral forces to be applied to the at least one or more of the optical modules so that those optical modules are transitioned from their non-skewed configuration to their skewed configuration. As discussed above and illustrated in FIG. 5, the skewed configuration occurs when a buffer encasement 36 is laterally deformed and the optical fiber ribbons 34 therein slide laterally relative to one another.

It is within the scope of the present invention for the enclosing of the optical modules in the longitudinally passage defined by the outer jacket 112 e to include operations prior thereto. For example, the lateral forces that result in the skewed configuration of optical modules 30 can be caused when the optical modules are drawn together in preparation for being enclosed in the outer jacket 112 e. As an additional example, in accordance with the twelfth embodiment, the group of optical modules 30 can be collectively encircled by water-blocking tape (for example, see the water-blocking tape 110 (FIG. 16)), and the application of the tape may result the lateral forces that result in the skewed configurations of at least some of the optical modules.

Thirteenth Embodiment

FIG. 21 is a schematic end elevation view of a fiber optic cable 118 a in accordance with a thirteenth embodiment of the present invention. The fiber optic cable 118 a includes multiple ribbon stacks 32 (for example see FIG. 4), which are preferably components of optical modules 30. More specifically, the fiber optic cable 118 a includes a longitudinally extending central member 120 a defining a longitudinally interior passage through which an optical module 30 longitudinally extends. The central member can be a relatively strong central strength member, or it can be a central spacer that is not as strong as the central strength member. The optical module 30 extending through the central member 120 a can be characterized as a central optical module. Multiple optical modules 30 are arranged radially around the periphery of the central member 120 a. Those radially arranged optical modules 30 can be characterized as peripheral optical modules.

In accordance with the thirteenth embodiment, the ribbon stack 32 (see FIG. 4 for example) of the central optical module 30 is in the form of a stack of twelve optical fiber ribbons 34 (see FIG. 3 for example) with each of those optical fiber ribbons containing twelve optical fibers 38 (see FIG. 3 for example). In accordance with the thirteenth embodiment, each of the peripheral optical modules 30 is in the form of a stack of twelve optical fiber ribbons 34 with each of those optical fiber ribbons containing twelve optical fibers 38. Therefore, the optical fiber cable 118 a has a total fiber count of 1008. Variations of the optical fiber cable 118 a have different fiber counts.

In accordance with the thirteenth embodiment, each of the optical modules 30 have approximately the same height H (FIG. 2) and each of the optical modules have approximately the same width W (FIG. 2). In the end elevation view of the fiber optic cable 118 a, for each of the peripheral optical modules 30 the height H is the radial cross-dimension of the peripheral optical modules, with the radial directions extending from the center of the center optical module 30 toward the peripheral optical modules.

Longitudinally extending strength members 122 extend between the peripheral optical modules 30, and a longitudinally layer of armor 124 a encircles the peripheral optical modules. A longitudinally extending outer jacket 126 a constructed of a polymeric material extends around the armor 124 a. In accordance with the thirteenth embodiment, the central optical module 30 is approximately centrally located with respect to the outer jacket 126 a, and a radial distance is defined between the center of the central optical module and the center of each of the peripheral optical modules 30. The radial distances defined between the center of the central optical module 30 and the center of each of the peripheral optical modules 30 are approximately equal.

In accordance with one version of the thirteenth embodiment, voids within the fiber optic cable 118 a are filled with a conventional flooding material, such as a thixotropic gel. In contrast, in accordance with another version of the thirteenth embodiment, interior spaces of the fiber optic cable 118 a are not filled with a flooding material, such as a thixotropic gel.

In accordance with a first version of the thirteenth embodiment, the peripheral optical modules 30 are not stranded. In accordance with this first version, it is preferred for the central member 120 a not to define a lay length. For example, FIG. 22 is an isolated perspective view of the central member 120 a of the fiber optic cable 118 a (FIG. 21) in accordance with the first version of the thirteenth embodiment. As illustrated in FIG. 22, the outer surface of the central member 120 a does not define a lay length.

In accordance with a second version of the thirteenth embodiment, the peripheral optical modules 30 are longitudinally stranded around the central member 120 a. In accordance with one example, the peripheral optical modules 30 are helically stranded around the central member 120 a, and in accordance with another example the peripheral optical modules are S-Z stranded around the central member. In accordance with this second version, it is preferred for portions of the exterior surface of the central member 120 a to define the same type of stranding and lay length as the peripheral optical modules. For example, FIG. 23 is an isolated perspective view of the of the central member 120 a of the fiber optic cable 118 a (FIG. 21) in accordance with the second version of the thirteenth embodiment.

As best seen in FIG. 21, the outer surface of the central member 120 a defines a six-sided polygon-like shape, and the fiber optic cable 118 a contains a corresponding number of peripheral optical modules 30. In accordance with an alternative to the thirteenth embodiment, the outer surface of the central member 120 a defines a circular shape. In accordance with another alternative to the thirteenth embodiment, the fiber optic cable 118 a does not include the central member 120 a, in which case stranding of the peripheral optical modules 30 is with respect to the central optical module 30.

Fourteenth Embodiment

FIG. 24 is a schematic end elevation view of a fiber optic cable 118 b in accordance with a fourteenth embodiment of the present invention. The fiber optic cable 118 b of the fourteenth embodiment is identical to the fiber optic cable 118 a (FIG. 21) of the thirteenth embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

In accordance with the fourteenth embodiment, each of the optical modules 30 of the fiber optic cable 118 b have approximately the same width W (FIG. 2), and the height H (FIG. 2) of the central optical module 30 is greater than the height H of the peripheral optical modules 30. Incorporating optical modules 30 having different heights H and/or widths W advantageously provides for flexibility in cable designs and efficient packaging of optical fibers in fiber optic cables with high fiber counts.

In accordance with the fourteenth embodiment, the ribbon stack 32 (see FIG. 4 for example) of the central optical module 30 is in the form of a stack of eighteen optical fiber ribbons 34 (see FIG. 3 for example) with each of those optical fiber ribbons containing twenty-four optical fibers 38 (see FIG. 3 for example). In accordance with the fourteenth embodiment, each of the peripheral optical modules 30 is in the form of a stack of six optical fiber ribbons 34 with each of those optical fiber ribbons containing twenty-four optical fibers 38.

Therefore, the optical fiber cable 118 b has a total fiber count of 1296. Variations of the optical fiber cable 118 b have different fiber counts.

Fifteenth Embodiment

FIG. 25 is a schematic end elevation view of a fiber optic cable 118 c in accordance with a fifteenth embodiment of the present invention. The fiber optic cable 118 c of the fifteenth embodiment is identical to the fiber optic cable 118 a

(FIG. 21) of the thirteenth embodiment, except for noted variations and variations apparent to those of ordinary skill in the art.

In accordance with the fifteenth embodiment, both the height H (FIG. 2) and the width W (FIG. 2) of the central optical module 30 is greater than the height H and width W of each of the peripheral optical modules 30. In accordance with the fifteenth embodiment, the ribbon stack 32 (see FIG. 4 for example) of the central optical modules 30 is in the form of a stack of eighteen optical fiber ribbons 34 (see FIG. 3 for example) with each of those optical fiber ribbons containing twenty-four optical fibers 38 (see FIG. 3 for example). In accordance with the fifteenth embodiment, each of the peripheral optical modules 30 is in the form of a stack of twelve optical fiber ribbons 34 with each of those optical fiber ribbons containing twelve optical fibers 38. Therefore, the optical fiber cable 118 c has a total fiber count of 1296. Variations of the optical fiber cable 118 c have different fiber counts.

Sixteenth Embodiment

FIG. 26 is a schematic end elevation view of a fiber optic cable 118 d in accordance with a sixteenth embodiment of the present invention. The fiber optic cable 118 d of the sixteenth embodiment is identical to the fiber optic cable 118 c (FIG. 25) of the fifteenth embodiment, except for noted variations and variations apparent to those of ordinary skill in the art. In accordance with the sixteenth embodiment, the outer surface of the central member 120 d defines an eight-sided polygon-like shape and there are eight peripheral optical modules. Therefore, the optical fiber cable 118 d has a total fiber count of 1584.

The fiber optic cables 118 a-c (FIGS. 21 and 24-26) illustrate that in fiber optic cables of this type, maximum packaging efficiency may be achieved with a central stack of optical fiber ribbons with relatively wide (relatively high fiber count) ribbons and peripheral stacks of optical fiber ribbons with relatively narrow (relatively low fiber count) ribbons.

Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

That which is claimed:
 1. A fiber optic cable with efficiently packaged optical fibers, comprising: a jacket extending in a longitudinal direction and defining a longitudinally extending jacket passage; and a plurality of longitudinally extending stacks of optical fiber ribbons, wherein each stack is within the jacket passage, each optical fiber ribbon comprises a laterally extending array of longitudinally extending optical fibers that are bonded together as a unit, each optical fiber ribbon comprises a pair of longitudinally extending opposite edges and a pair of opposite lateral surfaces that extend laterally between the edges, the plurality of stacks comprises a central stack that is approximately centrally located in the jacket passage and peripheral stacks positioned radially around the central stack in an end elevation view of the fiber optic cable, in the end elevation view thereof the periphery of each stack defines a first cross-dimension between a first pair of opposite sides that are defined by edges of the optical fiber ribbons of the stack, in the end elevation view thereof each stack further defines a second cross-dimension between a second pair of sides that are defined by one of the lateral surfaces of one of the optical fiber ribbons of the stack and one of the lateral surfaces of another of the optical fiber ribbons of the stack, and a difference exists between the central stack and all of the peripheral stacks of the fiber optic cable, wherein the difference is selected from the group consisting of: the first cross-dimension of the central stack is larger than the first cross-dimensions of all of the peripheral stacks of the fiber optic cable, and the second cross-dimensions of the central stack is larger than the second cross-dimensions of all of the peripheral stacks of the fiber optic cable.
 2. A fiber optic cable according to claim 1, further comprising a plurality of buffer encasements respectively containing the peripheral stacks, wherein each buffer encasement comprises longitudinally extending interior surface, each interior surface extends around and defines a longitudinally extending passage that contains the respective peripheral stack, and each interior surface closely bounds and engages the periphery of the respective peripheral stack.
 3. A fiber optic cable according to claim 1, wherein the first and second cross-dimensions of the central stack are larger than the first and second dimensions of the peripheral stacks.
 4. A fiber optic cable according to claim 1, wherein in the end elevation view thereof, the periphery of each stack defines a generally parallelogram-like shape.
 5. A fiber optic cable according to claim 1, wherein for each stack the first cross-dimension thereof is approximately equal to the second cross-dimension thereof.
 6. A fiber optic cable according to claim 5, wherein the first and second cross-dimensions of the central stack are larger than the first and second dimensions of the peripheral stacks.
 7. A fiber optic cable, comprising: a plurality of optical modules, wherein each optical module comprises: a stack of optical fiber ribbons extending in a longitudinal direction, wherein each optical fiber ribbon comprises a laterally extending array of longitudinally extending optical fibers bonded together as a unit and a pair of opposite edges that extend in the longitudinal direction, and a one-piece buffer encasement comprising longitudinally extending interior and exterior surfaces, wherein the interior surface extends around and defines a longitudinally extending passage that contains the stack, with the interior surface closely bounding and engaging a substantial portion of the periphery of the stack so that for each optical fiber ribbon the interior surface of the buffer encasement engages each of the edges of the optical fiber ribbon; a central member around which the optical modules are longitudinally stranded; and a longitudinally extending jacket defining a longitudinally extending jacket passage through which the central member and the optical modules extend, wherein for each optical module the stack is in a longitudinally twisted configuration and the buffer encasement is a sheath that is thin such that the exterior surface of the sheath defines ridges that correspond to the twist of the stack, and the ridges are at comers of the sheath that are respectively positioned at comers of the stack that is enveloped by the sheath.
 8. A fiber optic cable according to claim 7, wherein for each optical module: each optical fiber ribbon comprises a pair of longitudinally extending opposite edges and a pair of longitudinally extending opposite surfaces that extend laterally between the edges, and each optical fiber ribbon has a thickness defined between its opposite surfaces; and the buffer encasement is a relatively thin sheath, in an end elevation view of the sheath at least a majority of the sheath has a thickness defined between the interior and exterior surfaces that is not substantially greater than the thickness of each of the optical fiber ribbons.
 9. A fiber optic cable according to claim 7, wherein for each optical module: in an end elevation view of the stack the periphery of the stack defines a shape; and in the end elevation view of the buffer encasement the interior surface of the buffer encasement defines a shape that is substantially similar to the shape defined by the periphery of the stack in the end elevation view of the stack.
 10. A fiber optic cable according to claim 9, wherein for each optical module, in the end elevation view of the buffer encasement, the exterior surface of the buffer encasement defines a shape that is substantially similar to the shape defined by the periphery of the stack in the end elevation view of the stack.
 11. A fiber optic cable according to claim 7, wherein for each optical module, the interior surface of the buffer encasement is unadhered to the stack and the stack is capable of moving longitudinally relative to the stack.
 12. A fiber optic cable with efficiently packaged optical fibers, comprising: a jacket extending in a longitudinal direction and defining a longitudinally extending jacket passage; a plurality of longitudinally extending stacks of optical fiber ribbons, wherein each optical fiber ribbon comprises a laterally extending array of longitudinally extending optical fibers that are bonded together as a unit and a pair of opposite edges that extend in the longitudinal direction, each stack is within the jacket passage, and the plurality of stacks comprises: a central stack that is approximately centrally located in the jacket passage, and peripheral stacks positioned radially around the central stack in an end elevation view of the fiber optic cable; a plurality of one-piece buffer encasements respectively containing the peripheral stacks and longitudinally stranded around the central stack, wherein each buffer encasement comprises a longitudinally extending interior surface, each interior surface extends around and defines a longitudinally extending passage that contains the respective peripheral stack, and each interior surface closely bounds and engages a substantial portion of the periphery of the respective peripheral stack so that for each optical fiber ribbon the interior surface of the respective buffer encasement engages each of the edges of the optical fiber ribbon; and a longitudinally extending central member defining a longitudinally extending central passage, wherein the central stack is within the central passage, and the buffer encasements are longitudinally stranded around the central member, and wherein the central member has a longitudinally extending exterior surface and in an end elevation view of the central member the exterior surface defines a generally polygon-like shape, and the polygon-like shape has a number of sides that corresponds to the number of peripheral stacks.
 13. A fiber optic cable according to claim 12, wherein: the central stack that is approximately centrally located in the jacket passage, and a radial distance is defined between the center of the central stack and the center of each of the peripheral stacks, and the radial distances defined between the center of the central stack and the center of each of the peripheral stacks is approximately equal.
 14. A fiber optic cable according to claim 12, wherein each of the peripheral stacks is longitudinally twisted within its buffer encasement to define a lay length.
 15. A fiber optic cable according to claim 12, wherein: the central member has a longitudinally extending exterior surface that defines a lay length; and the longitudinally stranded peripheral stacks define a lay length that is equal to the lay length defined by the exterior surface of the central member.
 16. A fiber optic cable according to claim 2, wherein each buffer encasement is a one-piece buffer encasement and for each of the optical fiber ribbons the interior surface of the respective buffer encasement engages each of the edges of the optical fiber ribbon. 